Krulak purchased Full Stack’s technology along with the factory that houses it from his former employer, real estate developer Forest City Ratner, in 2016. “With metrology, you can see if the module is going to fit the way it is supposed to.” “When you are constructing a 30-story building, the dimensional tolerances go way down because if your measurements are off you end up with the Leaning Tower of Pisa,” explained Krulak. Metrology, or the science of measurement, can be used to determine how something built in the factory will fit when it is arranged on-site. Full Stack uses 3D modeling and a process known as metrology to assure they are building their structures to spec. Krulak says this process is safer, less wasteful and guarantees time and cost predictability.Īdvancements in technology have made this type of construction possible. They then create an assembly line organized by efficiency, and use a team of trade associates to build the modules. Some processes can be automated while others require skilled workers.
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“We are just trying to steer this industry towards progress.”įull Stack Modular approaches the construction of a building by creating an electronic production model of what is going to be built and all of the instructions on how to do it. “Pretty much everything in the world people use on a regular basis is manufactured, except buildings,” said Krulak. His solution? Make the construction process resemble manufacturing. Among the issues, Krulak says, is that architects, developers and contractors all have competing interests, which leads to projects going over budget and being completed late. Krulak is a 35-year veteran of the building industry who launched Full Stack under the belief that the current system of construction is broken. “It’s simpler and more effective than what we have now.” “It’s pretty much Legos and Erector Sets,” said CEO Roger Krulak, who founded Full Stack Modular in 2016. This is what work is like inside Full Stack Modular, a 100,000-square-foot factory in the Brooklyn Navy Yard that builds modular housing - a form of construction where a structure is built in pieces (or modules) in a factory and then assembled at the construction site (also known as prefabricated housing).
A steel frame moves from workstation to workstation, first being outfitted with wall panels, then threaded with electrical wiring and plumbing, and finally mounted to a steel chassis to form one wall of a bathroom “pod.” This pod will then be slotted into a larger module comprising a bedroom and kitchen, and the full module will be stacked atop similar modules, forming a multi-level apartment building.
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